PNEUMATIC MOTOR FOR PUMPS Stroke : 120 mm
Contents
1. Name and address of the manufacturer Motor part number and serial number The two first numbers indicate the manufacturing year Il group ll 2 class 2 Surface equipment meant to area where explosive atmospheres due to gas vapours mists or air mixtures with dusts are liable to appear from time to time in usual operating G gas E CONNECTIONS OF THE SUBSETS PNEUMATIC SUPPLY Any restrictive operation on motor air supply and or exhaust can reduce its efficiency The maximum air supply is 6 bars 87 psi KREMLIN REXSON Page 7 Manual 574 150 112 04 OPERATING m EXPECTED USE These pneumatic motors are designed to be coupled with the recommended KREMLIN REXSON fluid section to get the required ratio and flow rate refer to the document concerning the pumps E OPERATING DESCRIPTION The KREMLIN REXSON pneumatic motors with rectilinear alternative motions operate thanks to compressed air supply The reversing system is carried out by means of adistributor model 4 2 two sensors distributor model 5 2 05 USE Guards air motor cover coupling shields housings have been designed for a safe use of the equipment The manufacturer will not be held responsible for bodily injury or failure and or damage to property due to removal or partial removal of the guards ADJUSTMENT The increase of the motor supply air pressure via the air regulator leads to an increase of the number2. STORING Place the equipment safe from dampness after having closed the different air inlets and ports plugs E DIMENSIONS AND FEATURES A mm 204 8 204 8 262 10 3 262 10 3 324 12 7 324 12 7 mm 345 13 5 345 13 5 400 15 7 400 15 7 462 18 2 462 18 2 C mm 440 17 3 High neutral grear 63 5 2 5 137 5 4 237 9 3 137 5 4 237 9 3 137 5 4 HNG mm Cylinder bore mm 190 7 5 190 7 5 250 9 8 250 9 8 310 12 2 310 12 2 Practical stroke mm 120 4 7 Maximum stroke 132 5 mm 2 1 Noise level average Kg Lbs 21 46 3 21 46 3 26 57 3 26 57 3 35 77 1 35 77 1 KREMLIN REXSON Page 6 Manual 574 150 112 TAPPING OF THE LOWER FLANGES Oo ON MOTC MOTORS Co m Er MOTORS REF 105251 REF 105271 REF 105281 REF 105261 5 E i y c M12 on 05 20 132 mm M18 on 7 09 in 180 mm M18 on 2 6 30 in 160 mm E DESCRIPTION OF THE LABEL MARKING MOTEUR MOTOR MOTOR Marking in accordance with the ATEX directive EXSON France
3. t Kremlin Rexson INSTRUCTION MANUAL PNEUMATIC MOTOR FOR PUMPS Stroke 120 mm 4 72 in Series 5000 105251 Series 6000 105261 Series 7000 105271 Series 9000 105291 Series 7120 105270 Series 9120 105290 Manual 574 150 112 1111 MOT1 Date 21 11 11 Supersede 01 06 07 Modif Update TRANSLATION OF THE ORIGINAL MANUAL IMPORTANT Before assembly and start up please read and clearly understand all the documents relating to this equipment professional use only THE PICTURES AND DRAWINGS ARE NON CONTRACTUAL WE RESERVE THE RIGHT TO MAKE CHANGES WITHOUT PRIOR NOTICE KREMLIN REXSON 150 avenue de Stalingrad 93 245 STAINS CEDEX France T 33 0 1 49402525 33 0 1 48 26 07 16 www kremlin rexson com 01 02 03 04 05 06 07 08 T Kremlin Rexson INSTRUCTION MANUAL PNEUMATIC MOTOR FOR PUMPS TABLE OF CONTENTS WARRANTY E E EEE EEr E ER 2 SAFETY INSTRUC TIONS en A 2 INSTALLA NON m 0 9 SS 6 ez ggcmee er 8 USE S 8 ilz nypezeiiE cme e 10 MAINTENANCE SXS0SSS SS0Sn0nn0SnS0
4. and the safety instructions These instructions are available in the equipment manuals The motor is designed to be mounted with pump Never modify any components or T couplings When operating please keep hands away from moving parts Before starting up the equipment please read the PRESSURE RELIEF instructions Please ensure that any relief or drain valves fitted are in good working order HOSES e Keep hoses out of circulation areas moving parts or hot surfaces e Never expose product hoses to temperature higher than 60 C 140 F or lower than 0 C 32 F e Never pull or use the hoses to move the equipment e Tighten all fittings as well as the hoses before operating the equipment e Check the hoses regularly change them if they are damaged Never exceed the working pressure WP indicated on the hose lt DANGER EEE WARNING USED PRODUCTS Considering the wide variety of products that are available and can be used in our equipment itis impossible to check and make recommendations for all chemical data regarding the risks of possible chemical attack and their long term chemical reaction KREMLIN REXSON can not be held liable for Compatibility of wetted parts e Risks to staff and the surroundings e for worn or defective parts for faulty equipment or units or the quality of final product It is the responsibility of the user to know and prevent any possible risks such as toxic vapours fires or
5. appropriate container never place materials in a container where there is a risk of spillage or leakage e aprocedure must be applied for the safe disposal of waste material It must comply with all prevailing regulations and legislations of the country where the equipment is to be used protective clothing should always be worn in compliance with the material manufacturers recommendations e depending on the application and chemical safety instructions safety glasses hearing protective earplug gloves foot wear protective masks and possible breathing equipment should be worn to comply with the regulations Refer to chapter Safety equipment of KREMLIN selection guide erp KREMLIN REXSON Page 3 Manual 574 150 112 CAUTION It is forbidden to use material containing high concentrations of halogenated hydrocarbon solvents with aluminium or zinc fillers Non compliance with the instructions may cause explosion risk causing serious or fatal injury EQUIPMENT REQUIREMENTS Guards air motor cover coupling shields housings have been designed for a safe use of the equipment The manufacturer will not be held responsible for bodily injury or failure and or damage to property due to removal or partial removal of the guards PUMP Before carrying out any work it is imperative to read and clearly understand the disassembly and reassembly instructions before servicing The operator must understand the equipment
6. base seal F 4 Unscrew the 4 screws 38 and put aside the base 43 5 Remove the 2 base seals 44 6 Unscrew the 2 screws 30 and remove the U bolt 4 7 Unscrew the screws 27 and put aside the distributor sensors assembly 8 Unscrew the 2 screws 10 and remove the distributor 9 9 Unscrew the screws 7 and put aside the sensors 6 10 Remove the screw 31 and the cam 32 11 Change the defective parts The assembly is carried out in the reverse order of the disassembly sequence Caution to the following instructions During the changing of the sensors 6 push them in the opposite direction of the piston rod then tighten the screws The wheels must flush up the piston rod Cable once again the parts according to the pneumatic diagrams Orientate the distributor base seal 33 according to the A and B indexes Changing the seals of the upper and lower flanges and of the piston 1 Unscrew the screw 31 and remove the cam 32 2 Unscrew the 4 nuts 24 remove the washers 23 and the 4 screws 5 3 Remove the upper flange assembly 14 the cylinder 20 2 components polyurethan paint protection the lower flange assembly 22 and the rod piston assembly 4 Check the O Rings 15 of the flanges change them if necessary 5 Remove the screws 42 take off the stop flange 2 parts 19 and the adapter 2 parts 17 6 Take off the rod 8 downstream and remove the piston assembly 7
7. in the hole of the terminal Tighten the lock nut Connect the other end of the wire to a real ground according to the national rules A qualified electrician must check the ground continuity If the continuity is not correct check the terminal the electric wire the U bolt and the ground point Never operate pump without revolving the trouble CONNECTION TO THE COMPRESSED AIR SUPPLY For a correct operating and a long duration life of the motor supply air must be filtered and not lubricated Cf 5 Maintenance You must install a pressure relief valve after the air regulator and near to the inlet motor to follow the pressure relief instructions refer to pump instruction manual 5 Troubleshooting chart motor air supply hose should have an internal diameter of at least 19 mm 0 75 motors are tested prior to their sending Nonetheless before coupling the motor to the pump you must operate the no load motor during a few minutes to a maximum pressure of 1 bar 14 5 psi Then comply with the instructions as follows 1 Couple the motor to the required fluid section 2 Connect the main air supply to the motor 3 Adjust the pressure by means of the air regulator KREMLIN REXSON Page 5 Manual 574 150 112 03 INSTALLATION HANDLING The ring located above the cover is designed for the hoisting of the motor and must not be used for the handling of the complete machine Never immerse the motor
8. of pump piston returns mn cycles which leads to a flow rate increase and to an outlet pressure increase of the pumped material AIR CONSUMPTION OF THE MOTORS Pressure of the motors at 6 bar 87 psi 5000 1700 6000 1700 7000 2940 9000 4520 KREMLIN REXSON Page 8 Manual 574 150 112 5000 Cubic feet min m min 141 1801 124 3 5 106 340 89 3 2 5 70 6 2 0 58 1 5 35 3 17 6 0 5 at 7 psi 6 bar at 53 A bar at 29 psi bear 10 20 30 40 50 50 Pump cycles per minute Type 6000 Cubic festimin nrimin 141 4 0 1241351 106 3 00 98 3 2 5 2 0 520 1 5 35 3 1 0 at T psi G bai at 58 psi bar at 29 2 bar Pump cycles per minute E TROUBLESHOOTING CHART Type 7000 Cubic feet min m min 141 40 T24 3 5 106 3 0 83 3 2 5 at 87 psi 6 bar at 53 psi 4 bar at 29 psi 2 bai Pump cycles per minute Type 9000 Cubic feet min m min at 87 psi 6 bar at 53 psi 141 4 0 124 3 5 106 3 0 83 3 2 5 7 5 2 0 62 9 1 5 35 3 10 17 6 0 5 at 29 psi 2 bal Pump cycles per minute Carry out the pressure release instructions before any intervention shut off the air inlet using the release pressure valve to evacuate the residual air depressurize the material circuit opening the pump drain valve or the gun Caution Check the conformity of the cabling before a
9. safety instructions for this equipment as well as the instructions in the manuals for the different parts and accessories Read carefully all instruction manuals label markings before operating the equipment Incorrect use may result in injury This equipment is for professional use only It must be used only for what it has been designed for Never modify the equipment The parts and accessories supplied must be regularly inspected Defective or worn parts must be replaced Guards air motor cover coupling shields housings have been designed for a safe use of the equipment The manufacturer will not be held responsible for bodily injury or failure and or damage to property due to removal or partial removal of the guards Never exceed the equipment components maximum working pressure Comply with regulations concerning safety fire risks electrical regulations in force in the country of final destination of the material Use only products or solvent compatible with the parts in contact with the material refer to data sheet of the material manufacturer KREMLIN REXSON Page 2 Manual 574 150 112 PICTOGRAMS Nip hazard Warning moving Warning moving Warning moving Do not exceed High pressure elevator parts shovel this pressure hazard Relief or drain Warning hose Wear of glasses Wear of gloves is Product vapor Warning hot parts valve under pressure is obligatory obligatory hazard or areas Electrical hazard War
10. Check the O Ring 13 change it if necessary 8 Check the piston O Ring 16 change it if necessary then put aside the piston 18 The assembly is carried out in the reverse order of the disassembly sequence Caution to the following instructions Stage 5 Applicate ONE SEAL LOCTITE N 518 paste on the adapter 2 parts 17 as well as on the screws 42 to ensure the tightness between piston and rod Stage 8 Assembly of the piston floating seal 16 First insert the seal with a light coating of pneumatic grease in the groove of the piston Position the rod piston seal assembly above the cylinder Press on the sides of the seal until the piston rod assembly slides inside the cylinder KREMLIN REXSON Page 13 Manual 574 150 112 Changing the bearing seals 1 Unscrew the 4 screws 55 2 Remove the bearing assembly if necessary use the M6 tapping holes 3 Remove and check the seals 36 amp 37 change them if necessary Disassembly of the distributor 33 black SEALS KIT IET REF 105346 HAHHA INCLUDED IN KIT REF 105346 can not be sold separately 1 Disconnect the air hoses 2 Unscrew the 4 screws 34 which fix the distributor on the base remove the seal F check it and change it if necessary 3 Unscrew the 4 screws J which fix the cover C to the body M side A check the seal D change it if necessary 4 Unscrew the 4 screws J which fix the cover K to
11. Series 5000 6000 7000 9000 The motors mounted in our plant are cabled in the user wants to get a motor starting with a standard piloting The threshold of the motor starting pressure of about 0 5 bar 7 25 psi the cabling can is about 1 5 bar 21 7 psi be modified in direct piloting KREMLIN REXSON Page 11 Manual 574 150 112 07 E PREVENTIVE MAINTENANCE CAUTION BEFORE ANY INTERVENTION PLEASE FOLLOW THE PRESSURE RELEASE INSTRUCTIONS AND THE SAFETY INSTRUCTIONS The motor is manufactured under the ATEX agreement and can not be modified KREMLIN REXSON will not be held responsible for any failure to comply with that instruction Guards air motor cover coupling shields housings have been designed for a safe use of the equipment The manufacturer will not be held responsible for bodily injury or failure and or damage to property due to removal or partial removal of the guards The motor is designed to have a minimum maintenance supply air filtered We advice you to carry out a preventive maintenance after an operating of 12 months Check if the air filter is clogged that there is no air leakage that air hoses are not damaged that the connections between fittings and hoses are correct the correct condition of the supply hoses rubber setting regulators and gauges the tightening of the components the condition of the muffler s the fixing of t
12. ched from the date of delivery Work life is based on single shift working 8 hours per day Warranty claims for defective items will only be accepted in writing and will be verified and confirmed by us The warranty does not cover fair wear and tear damage or wear caused by misuse improper maintenance or non observance of our recommendations KREMLIN REXSON will repair or replace parts carriage paid to our plant and accepted as defective by us We shall not be liable for any losses resulting from a production breakdown Upon request we can carry out service work at your premises all expenses travelling and accommodation for KREMLIN REXSON technicians will be chargeable In the event that it is found that equipment has been tampered with this will invalidate the warranty Equipment that it is bought in will be subject to the suppliers warranty 02 SAFETY INSTRUCTIONS GENERAL SAFETY INSTRUCTIONS CAUTION The equipment can be dangerous if you do not follow our instructions concerning installation and servicing described in this manual and in accordance with applicable European standards and local national safety regulations Please carefully read all the instruction literature before operating your equipment Only trained operators can use the equipment To acquire an essential training please contact the KREMLIN REXSON University training center Stains The foreman must ensure that the operator has understood the
13. explosions He shall determine the risks of immediate reactions or pursuant to repeated exposures of the staff KREMLIN REXSON shall not be liable for physical injuries direct or indirect material damages caused by the use of chemicals KREMLIN REXSON Page 4 Manual 574 150 112 SPECIFIC SAFETY INSTRUCTIONS MOTOR LABEL IL Les fluides sous haute pression peuvent transpercer la peau et provoquer des blessures graves pouvant n cessiter l amputation Ecartez vous de la buse de pulverisation ou d extrusion N arr tez jamais une fuite avec main EN CAS DE BLESSURE CONSULTEZ UN MEDECIN IMMEDIATEMENT L installation dans des zones confin es de mat riels de pulverisatinn ou d extrusion de produit de rin age ou de nettoyage utilisant des liquides inflammables peut provoquer des incendies ou des explosions Les flammes nues les tincelles et les arcs lectriques peuvent enflammer des vapeurs inflammables i IMPORTANT LIMINER TOUTE SOURCE DE CHARGE ELECTROSTATIOUR A UE Reliez la terre tous les mat riels situ s dans la zone de travail y compris moto pompes les flexibles et les pieces a traiter loignez vous des pi ces en mouvement d passez pas les pressions maxi d utilisation de la moto pompe ni d aucun composant de l installation PRESCRIPTIONS DE S CURIT Lisez le manuel d instruction et ou d exploitation Suivre la procedure de decompression avant toute interventi
14. he cover the correct operating of the safety valve the condition of the relief valve DISASSEMBLY ASSEMBLY CAUTION READ THE SPARE PARTS LIST AND THE SERVICING KITS AVAILABLE Guards air motor cover coupling shields housings have been designed for a safe use of the equipment The manufacturer will not be held responsible for bodily injury or failure and or damage to property due to removal or partial removal of the guards The maintenance consists in changing the damaged parts and cleaning the parts with compatible materials without using abrasive materials which can damage them The O Rings are mounted with a pneumatic grease Make sure during the assembly that the seals are not damaged to avoid a bad operating of the motor KREMLIN REXSON Page 12 Manual 574 150 112 Disassembly of the motor and of the fluid section 1 Adjust the air regulator to 0 bar 0 psi 2 Shut off the air supply from the motor then carry out the pressure release and drain instructions 3 Take off the axis lock 21 4 Lift the closing ring 25 5 Take off the two half bushes 26 and put aside the closing ring 6 Remove the fixing screws of the motor 7 Put aside the motor Disassembly of the distributors and of the sensors 1 Unscrew the 2 screws 27 and remove the washers 28 2 Take off the cover 2 and disconnect the air hoses 3 Unscrew the 4 screws 34 put aside the distributor 33 and remove the
15. nSnS0n9SCL X 12 EXPLODED VIEW AND PARTS DENKE dE EHE REM DE 15 Dear Customer You are the owner of our new equipment and we would like to take this opportunity to thank you To make sure your investment will provide full satisfaction special care has been taken by KREMLIN REXSON during all designing and manufacturing processes To obtain the best result safe and efficient operation of your equipment we advice you to read and make yourself familiar with this instruction and service manual Indeed the non compliance with instructions and precautions stated in this manual could reduce the equipment working life result in operating trouble and create unsafe conditions KREMLIN REXSON Page 1 Manual 574 150 112 01 WARRANTY We reserve the right to make changes these changes be carried out after the receipt of the order No claim will be accepted as a consequence of any change carried out in the instruction manuals or in the selection guides Our equipment is checked and tested prior to shipment In the case of a problem arising with the equipment this must be in writing within ten days from the delivery date KREMLIN REXSON warrants all equipment manufactured bearing its name to be free from defect in material or workmanship for a period of 12 months one shift per day or 1800 hours 1 term rea
16. ning fire Explosion Grounding Warning User 754 serious hazards hazards ls d FIRE EXPLOSION SPARKS STATIC ELECTRICITY HAZARDS A poor earth connection inadequate ventilation sparks or static electricity can cause an explosion or fire to avoid these risks when using or servicing KREMLIN REXSON equipment the following safety procedures must be followed e ensure a good earth connection and ground the parts to be handled i e solvents materials components and equipment e ensure adequate ventilation keep working area clean and free from waste solvents chemicals or solid waste i e rags paper and empty chemicals drums never use electrical switches power if in an atmosphere of volatile solvent vapour stop working immediately in case of electrical arcs e never store chemicals and solvents in the working area e use paint whose flash point is the highest possible to prevent from any formation of gas and inflammable vapours refer to materials safety instructions e install a cover on the drums to reduce the diffusion of gas and vapours in the spraybooth TOXIC PRODUCT HAZARDS PED Toxic products or vapours can cause severe injury not only though contact with the body but also if the products are ingested or inhaled It is imperative to know the material products and their risks e notified or hazardous materials must be stored in accordance with the regulations e the material must be stored in an
17. ny intervention TROUBLES CAUSES SOLUTIONS Defective sensors Motor piston locked Defective power distributor Material flow rate drop Muffler clogged up Defective control distributor Leakage during the exhaust Adjust or change the sensor s Check the operating change if necessary Check the operating change if necessary Check the seals of the piston change them if necessary Check the seals of the distributor change them if necessary Clean or change the muffler Distributor base seal incorrectly Mount the seal correctly mounted Important leakage during the exhaust KREMLIN REXSON Power distributor defective Page 9 Check the operating change if necessary Manual 574 150 112 06 PNEUMATIC CABLING Pneumatic diagram 2 54 2 5 4 HIGH LIMIT SWITCH UP EXE 14 5 2 2 4 T 3 12 An 2 514 AIR REGULATOR 1 i t H j E NOT LUBRICATED FILTERED MAIN AIR INLET STANDARD L CABLING LEVEL TO START 29 psi 2 bar 2 5 4 g MINI 26 psi 1 8 bar m MAXI 116 psi 8 bar VERSION WITH DIRECT CONTROL not delivered LEVEL TO START lt 29 psi 2 bar m air hose Ratch a plug rep EE for E the version with direct control E H H H H 3 H di E KREMLIN REXSON Page 10 Manual 574 150 112
18. on sur la pompe V rifiez les flexibles et les raccords quotidiennement Avant l utilksation rincez l appareil avec un produit compatible pour liminer tout reste ventuel de produits d essai en usine TIQUETTES SECURITE DISPONIBLES GRATUITEMENT SUR DEMANDE MISE EN GARDE WARNING EI 17 45 EN Liquids under high pressure can pierce the skin causing serious injury and possible amputation Keep clear of qun nozzle or spray tip Never stop a leak with your hand IN CASE OF INJURY GET IMMEDIATE SURGICAL TREATMENT Spray painting flushing or cleaning equipment with flammable liquids in confined areas can result in fire or explosion Open flames sparks and electrical arcs can ignite flammable vapars IMPORTANT ELIMINATE ALL IGNITION SOURCES Ground all equipment in spray area including pumps hoses and objects being sprayed Keep clear of moving parts Do nat exceed pressure rating of pump or any system component SAFETY INSTRUCTIONS Read instructions manual user manual Relieve pressure before servicing pump Check hoses and fittings daily Before using flush unit with material or solvent to remove any remaining factory test fluid 1 REXSON SAFETY TAGS FREE OF CHARGE REQUEST GROUNDING OF THE PUMP Unscrew the lock nut A introduce between the washers B the end of a ground wire D minimum section 1 5
19. s are not serviceable separately KREMLIN REXSON Page 17 Manual 574 150 112
20. the body M side B check the seal H and change it if necessary 5 Take off the valve E the spring guide L and the spring G 6 Carry out the assembly in the reverse order of the disassembly sequence KREMLIN REXSON Page 14 Manual 574 150 112 08 EXPLODED VIEW AND PARTS LIST n py Na i 2 SEAL KIT 29 MOTORS TYPES 5000 0 18 2 5 6000 0 18 2 5 TORQUE Itb 7000 0 36 5 0 9000 0 73 10 KREMLIN REXSON Page 15 Manual 574 150 112 105251 105270 105271 105250 105251 2046 205501 260s 205501 200508 205501 1 7 Sese motor 105263 105268 105273 105273 105208 KREMLIN REXSON Page 16 Manual 574 150 112 1 gt 105 270 105 271 ma oo em em ums em 4 4 a Baesel 777 NOS NS 2 RN 3 2 lwoo O o sm 1 s 2 17 Fe ma wem ty 1 1 1 1 2 1 1 1 2m 7 im 2 1 1 2 1 2 1 1 4 Seal kit Motor Description Qty 105 263 T 1 105 273 Seal kit ind 13 15 x2 16 36 x2 37 x2 44 x2 105 293 Preceding the index number denotes a suggested spare part N S S Denotes part
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